External structure heat sink

ABSTRACT

Systems and methods for dissipating heat from an electrical component using an external structure of a trailer or shed as a heat sink are disclosed. A heat-producing electrical component such as a variable frequency drive (VFD) using an insulated-gate bipolar transistor (IGBT) is housed in a trailer and is thermally coupled to an exterior wall of the trailer to use the wall as a heat sink to dissipate heat from the VFD and IGBT. An adapter can be used to couple VFDs and IGBTs of different sizes and configurations to a support site on the exterior wall.

This application claims priority as a divisional application of U.S.nonprovisional application Ser. No. 15/664,041 with the same title filedon Jul. 31, 2017 which claims priority to U.S. provisional patentapplication No. 62/370,229 filed Aug. 2, 2016 and U.S. provisionalpatent application No. 62/368,705 filed Jul. 29, 2016. All threeapplications in their entireties are incorporated by reference herein.

BACKGROUND

Oil and gas operations require many components and much power tooperate. Equipment such as drill motors, mud pumps, shakers, and manyother components are used in remote locations and in challengingenvironments. Some drill rigs have employed trailers or other temporaryinstallations equipped with electrical and mechanical equipment to helpmanage certain aspects of the drilling operation. Some common componentsfound in these trailers include mud pumps, drawworks, top drives, andvariable frequency drives (VFDs). VFDs (also known asadjustable-frequency drives, variable speed drives, AC drives, microdrives, or inverter drives) are a type of adjustable-speed drive used inelectro-mechanical drive systems to control AC motor speed and torque byvarying motor input frequency and voltage. VFDs are used in applicationsranging from small appliances to large compressors. VFDs produce heat ata high rate that must be dissipated somehow to ensure proper operationand longevity of the components.

SUMMARY

Embodiments of the present disclosure are directed to an apparatusincluding a structure having an external wall and a variable frequencydrive installed inside the structure. The variable frequency drive canhave an insulated-gate bipolar transistor (IGBT) on a rear face of thevariable frequency drive. The apparatus also includes an internal heatexchanger coupled to the rear face of the variable frequency drive andto a portion of the external wall. The internal heat exchanger conductsheat away from the IGBT and the external wall conducts heat away fromthe external heat exchanger. The apparatus also includes an externalheat exchanger coupled to the external wall opposite the internal heatexchanger that conducts heat from the external wall. The apparatus canalso include an adapter to thermally interface between the external walland the interior heat exchanger. The external wall has a recess and theadapter is configured to fit at least partially within the recess. Theadapter has a first side configured to conform to a portion of theexternal wall and a second side configured to conform to the internalheat exchanger.

Other embodiments of the present disclosure are directed to an apparatusfor supporting electrical components and dissipating heat generatedthereby. The apparatus can include a housing having an exterior wall andan electrical component within the housing, the electrical componenthaving a heat-producing surface. It also has an adapter thermallycoupled between the exterior wall of the housing and the heat-producingsurface. The exterior wall of the housing has at least twice as muchsurface area as the heat-producing surface. The apparatus also has aheat exchanger coupled to the exterior wall.

Still further embodiments of the present disclosure are directed to amethod including providing a structure having an electrical componentsupport site, determining a configuration of heat-producing componentsof an electrical component, and providing at the electrical componentsupport site on the structure an adapter with a plurality of panels. Theadapter can thermally couple an electrical component with the structuresuch that the structure serves as a heat sink for the electricalcomponents. The method also includes arranging the panels to includeheat exchangers in panels corresponding to the heat-producing componentsand blanks in panels not corresponding to the heat-producing components,and coupling the electrical component to the structure via the adapter.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a perspective wireframe illustration of a trailer includingvarious mechanical and electrical components according to embodiments ofthe present disclosure.

FIG. 2 is a top view of the trailer according to embodiments of thepresent disclosure.

FIG. 3 is a schematic cut away top view of a variable frequency drive(VFD) and heat dissipating components shown in detail A of FIG. 2according to embodiments of the present disclosure.

FIG. 3A is a sectional view of an internal heat exchanger according toembodiments of the present disclosure.

FIG. 4a is a schematic cut away top view of a VFD in a similarperspective as FIG. 3 according to embodiments of the presentdisclosure.

FIG. 4b is a schematic cut away top view of a VFD similar to FIG. 4bwith a different adapter configuration according to embodiments of thepresent disclosure.

FIG. 5 is a schematic illustration of an adapter and multiple internalheat exchangers according to embodiments of the present disclosure.

FIG. 6 shows the adapter and panels of FIG. 5 and insulated-gate bipolartransistors (IGBTs) installed according to embodiments of the presentdisclosure.

DETAILED DESCRIPTION

Below is a detailed description of apparatuses, systems, and methods forcooling electrical, mechanical, or industrial equipment using anexterior structure as a heat sink according to various embodiments ofthe present disclosure. FIG. 1 is a perspective wireframe illustrationof a trailer 10 including various mechanical and electrical componentsaccording to embodiments of the present disclosure. The trailer 10includes an outer structure including a roof 12, a door 14, and walls16. The trailer 10 can be any physical structure such as a shed, a case,or a trailer. It may be big enough for personnel to enter or it may bebuilt to house only the equipment. It may itself be housed insideanother structure, or it can be outside exposed to ambient conditions.There can be any number of components installed in the trailer 10. Oneof these components is a VFD 18. The VFD 18 is constructed as arectangular unit which stands in the trailer 10. Conventionally, VFDsare intended to be placed indoors and are cooled by an HVAC system inthe building. With a trailer 10 or other similar installation however,the HVAC systems are less robust and inefficient when it comes tocooling such equipment.

FIG. 2 is a top view of the trailer 10 according to embodiments of thepresent disclosure. The VFD 18 is shown installed with a backsideagainst the wall 16. Various other electrical and mechanical componentsare installed in the trailer 10 and the features and aspects of thepresent disclosure can also be applied to other components. For purposesof brevity and conciseness this disclosure will refer to the VFD 18 anddescribe systems and methods to dissipate heat generated by the VFD 18.Other components also generate heat and can be treated in similarfashion. There may be multiple VFDs 18 in a given installation. The heatfrom a VFD is primarily produced by an insulated-gate bipolar transistor(IGBT) which is an electronic switching (on/off) device and a primarycomponent in VFD inverters. Dissipating the heat produced by the IGBTswill prolong the longevity of the components and promote efficientoperation and prevents failure due to overheating. Many installationsare limited in the size and amperage of the VFD they can implementbecause of the heat produced. The systems and methods disclosed hereinwill mitigate these constraints, permit redundant cooling methods tomitigate the constraints or loss of amperage capability due to theability to operate liquid, air, or both media.

FIG. 3 is a schematic cut away top view of a VFD and heat dissipatingcomponents shown in detail A of FIG. 2 according to embodiments of thepresent disclosure. The VFD 18 includes an IGBT 20 on a backside of theVFD 18. There is internal heat exchanger 22 contacting the IGBT 20 andthe wall 16, and an external heat exchanger 24 contacting the wall 16.These components operate together to dissipate heat from the IGBT 20 andinto the environment, using the size and thermal capabilities of thewall of the trailer 10 as a heat sink to promote heat dissipation. TheIGBT 20 is shown as being co-extensive with the VFD 18. In someembodiments the IGBT 20 is smaller than the VFD in which case theinternal heat exchanger 20 and external heat exchanger 24 can be sizedaccordingly. The internal heat exchanger 22 can be a liquid coolingunit. FIG. 3a is a schematic side view of an internal heat exchanger 22according to embodiments of the present disclosure. The internal heatexchanger 22 can include coils 26 which can conduct a coolant such aswater or refrigerant or any other suitable cooling medium through thecoils 26. The coolant can be circulated under pressure to continuallyremove heat from the IGBT 20. The internal heat exchanger 22 or theexternal heat exchanger 24 or both can be thermally coupled to an HVACsystem of the trailer 10 or to ambient air. The internal heat exchanger22 can operate with air instead of liquid. Other cooling mechanisms canbe employed as well.

The wall 16 is shown in cut away section, but it can be much larger thanthe VFD 18. The large size of the wall 16 make it an excellent heat sinkfor heat produced by the VFD 18 and IGBT 20. The wall 16 can bethermally coupled to other components of the trailer 10, including theroof 12, door 14, and even the floor. The trailer 10 can be constructedout of a thermally conductive material such as aluminum or steel. Insome embodiments the joints between components of the wall 16 can bethermally conductive such that heat can dissipate from the portion ofthe wall 16 contacting the VFD 18 to other remote portions of thetrailer structure.

The external heat exchanger 24 is shown including a plurality of finsextending outward from the wall 16. Fins are chosen to increase surfacearea of the exchanger. Other configurations are possible, including asimple flat plate of thermally conductive material. The external heatexchanger 24 can also be cooled by ambient air, or an HVAC system of thetrailer 10 can blow air or another suitable fluid or gas over the fins.

FIG. 4a is a schematic cut away top view of a VFD 18 in a similarperspective as FIG. 3 according to embodiments of the presentdisclosure. The VFD 18, IGBT 20, internal heat exchanger 22, wall 16,and external heat exchanger 24 are shown and operate in a similar mannerto what is shown and described above with respect to FIGS. 3 and 3 a.The wall 16 has a cut out and there is an adapter 28 which has a firstside 30 facing inward toward the VFD 18 and a second side 32 facingtoward the wall 16. The adapter 28 is sized to accommodate the VFD 18,IGBT 20, and internal heat exchanger 22 on the first side, and toaccommodate the wall 16 on the second side. The adapter 28 can beinstalled into the wall 16 with the first side 30 flush with theinterior side of the wall 16, or with the second side 32 flush with theexterior side of the wall 16, or both the first side 30 and second side32 flush with the wall 16. The adapter 28 is shown with a steppedprofile 31 that matches a corresponding profile on the wall 16. Anysuitable profile 31 can be chosen to allow installation from theinterior or from the exterior, or both the interior or exterior.

FIG. 4b is a schematic cut away top view of a VFD 18 similar to FIG. 4bwith a different adapter configuration. The wall 16 has no cut out andinstead has a recess that does not pass all the way through the wall 16.The adapter 28, heat exchanger 22, and IGBT 20 are nested together inthermal contact with the wall 16. The profile of the adapter 28 isdifferent as well to accommodate the different shape of the wall 16 andrecess. In other embodiments the wall 16 can have no recess at all andinstead is flat. The wall 16 can still be coupled to the adapter 28 andother components. In some embodiments there is no adapter. The wall maybe flat or have a protruding support site that is configured to coupleto the heat exchanger 22 and the IGBT 20. In some embodiments there aremultiple components coupled to multiple support sites, whether they arecut outs, recesses, flat spaces, or protruding sites.

There can be multiple adapters 28 of different sizes to accommodatedifferent configurations. As stated elsewhere herein, the source of theheat can be any of the various components in the trailer 10 and therecan be a different adapter 28 for each component. The trailer 10 can bebuilt with multiple locations available for different adapters 28, toallow flexibility in constructing the trailer 10. Components can berearranged as needed. Different internal or external heat exchangers canbe used for different components according to their heat output or otherheat creation or insulation needs. The adapter 28 can be thermallyconductive with the wall 16 and the internal heat exchanger 22, theexternal heat exchanger 24, and even the IGBT 20 itself.

The present disclosure can also be constructed to address coldtemperatures. Any one or more of the internal heat exchanger 22, adapter28, wall 16, or external heat exchanger 24 can be changed to aninsulator to maintain heat within the components for a coldinstallation. The heat exchangers can be structurally the same but canbe operated in such a way to promote insulation rather than heatdissipation. This flexibility allows a manufacturer to construct asingle trailer 10 that can be suitable for use in any environment fromthe hottest to the coldest on earth.

FIG. 5 is a schematic illustration of an adapter 28 and multipleinternal heat exchangers 22 according to embodiments of the presentdisclosure. FIG. 5 shows an interior side of the adapter 28 with no VFDinstalled. The adapter 28 has four panels, 40 a, 40 b, 40 c, and 40 d.Panels 40 a, 40 c, and 40 d have heat exchangers 42 installed that canbe coextensive with the panel, while panel 40 b has a blank 44. In agiven installation there will be a need for a total amperage rating froma VFD. Because VFDs are manufactured at discrete amperage ratings and itis cost-prohibitive to custom order a VFD with precise amperage ratingsfor a given installation, it is common practice to operate any number ofVFDs together to arrive at a desired amperage. For example, supposethere is a need for 3000 amps from a VFD, but VFDs are available inratings of 250, 500, 1000, and 5000 amps. Three, 1000 amp VFDs can beput in each of panels 40 a, 40 c, and 40 d to reach the requiredamperage rating. The adapter 28 can have any number of panels, thepanels can be different sizes, and can have different heat dissipatingcharacteristics. The blank 44 can be essentially the same material asthe wall in which it will be found.

FIG. 6 shows the adapter 28 and panels 40 a-40 d of FIG. 5 and IGBTs 20installed according to embodiments of the present disclosure. A singleVFD can feature multiple IGBTs 20, and the panels and corresponding heatexchangers can be chosen to fit a given VFD configuration. The systemsand methods described herein allow for improved flexibility andefficiency for a trailer installation. The HVAC systems for the trailercan be smaller (and in some cases omitted entirely) than what would havebeen needed without the systems and methods of the present disclosure.The installation can fit a wide variety of heat-producing componentsusing different adapters and panels to fit the needs of the differentcomponents. Manufacturing costs are reduced because the trailer can beconstructed having any desired number of stations configured to receivean adapter. There can be any desired number of adapters which canaccommodate different components. The use of the heat exchangers and thesize of the wall for a heat sink will effectively manage the heat loadscreated by the components of the trailer.

The foregoing disclosure has been described with reference to thevarious figures and embodiments. It is understood by a person ofordinary skill in the art there may be variations or modifications notspecifically discussed that nevertheless fall within the scope of thepresent disclosure.

1. A method, comprising: providing a structure having an electricalcomponent support site; determining a configuration of heat-producingcomponents of an electrical component; providing at the electricalcomponent support site on the structure an adapter with a plurality ofpanels, the adapter being configured to thermally couple an electricalcomponent with the structure such that the structure serves as a heatsink for the electrical components; arranging the panels to include heatexchangers in panels corresponding to the heat-producing components andblanks in panels not corresponding to the heat-producing components; andcoupling the electrical component to the structure via the adapter. 2.The method of claim 1, further comprising operating the heat exchangersby running at least one of forced air or forced liquid through the heatexchangers.
 3. The method of claim 1, further comprising providing anexternal heat exchanger on an exterior surface of the structure.
 4. Themethod of claim 1, wherein the heat-producing components comprise aninsulated-gate bipolar transistor.
 5. The method of claim 1, wherein theadapter has a first side configured to conform to a portion of a paneland a second side configured to conform to the heat sink.
 6. The methodof claim 1, wherein the heat sink is a liquid-cooled heat exchanger. 7.The method of claim 1, wherein the heat sink is an air-cooled heatexchanger.
 8. The method of claim 1, wherein the heat sink is coupled toan HVAC system.
 9. The method of claim 1, wherein at least one of thepanels has an area that is at least twice as large as the rear face ofthe variable frequency drive.
 10. The method of claim 1, wherein theheat sink comprises a plurality of fins configured to passively transferthermal energy.
 11. An apparatus for supporting electrical componentsand dissipating heat generated thereby, the apparatus comprising: ahousing having an exterior wall; an electrical component within thehousing, the electrical component having a heat-producing surface; anadapter thermally coupled between the exterior wall of the housing andthe heat-producing surface, wherein the exterior wall of the housing hasat least twice as much surface area as the heat-producing surface; and aheat exchanger coupled to the exterior wall.
 12. The apparatus of claim11, wherein the electrical component is a variable frequency drive andan insulated-gate bipolar transistor.
 13. The apparatus of claim 11,wherein the housing comprises a trailer, the apparatus comprisingmultiple electrical components and multiple adapters, the adapters beingconfigured to thermally couple the electrical components and theexterior wall.
 14. The apparatus of claim 11, further comprising aninternal heat exchanger between the electrical component and theexterior wall, and wherein at least one of the heat exchanger and theinternal heat exchanger is a liquid-operated heat exchanger.